Apparatuses and methods for forming smart labels

ABSTRACT

Apparatuses and methods for forming displays are claimed. This invention relates to a display which may be conformal and which can receive information in order to alter or configure the display. In one embodiment, a flexible layer may be made to receive an array of blocks which drive a display material to provide an alterable or configurable display. This display is coupled to a receiver which receives data and drives the data onto the blocks causing the display to change. The receiver (and blocks) may be powered by a signal from a transmitter which beams the information to the receiver. The receiver in turn controls the update of the display information on the display. Another embodiment of the invention has a receiver coupled to each block. The receiver also may be independent from the block and may be deposited onto the flexible layer.

RELATED APPLICATION

This application is a continuation of co-pending U.S. application Ser.No. 11/641,455, filed Dec. 18, 2006, entitled “Apparatus and Methods forForming Wireless RF Labels”, which is a continuation of co-pending U.S.application Ser. No. 09/932,644, filed Aug. 17, 2001, entitled“Apparatus and Methods for Forming Smart Labels”, now U.S. Pat. No.7,218,527, which is hereby incorporated herein by this reference in itsentirety.

FIELD OF THE INVENTION

The present invention relates generally to electronic assemblies. Moreparticularly, the present invention relates to apparatuses and methodsfor forming displays that are alterable and configurable based upon datathat is received from a transmitter.

DESCRIPTION OF RELATED ART

Display panels are used in a variety of devices to convey information.Display panels may be comprised of active matrix or passive matrixpanels. Active matrix and passive matrix panels may be eithertransmissive or reflective. Transmissive displays include bothpolysilicon thin-film transistor (TFT) displays and high-resolutionpolysilicon displays. Reflective displays typically comprise singlecrystal silicon integrated circuit substrates which have reflectivepixels.

Liquid crystals, electroluminescent (EL) materials, organic lightemitting diodes (OLEDs), upconverting and downconverting phosphor(U/DCP), electrophoretic (EP) materials, or light emitting diodes (LEDs)may be used in fabricating flat-panel display panels. Each of these isknown in the art and is discussed briefly below. Liquid crystal displays(LCDs) may have an active matrix backplane in which thin-filmtransistors are co-located with LCD pixels. Flat-panel displaysemploying LCDs generally include five different components or layers: aWhite or sequential Red, Green, Blue light source, a first polarizingfilter that is mounted on one side of a circuit panel on which the TFTsare arrayed to form pixels, a filter plate containing at least threeprimary colors arranged into pixels, and a second polarizing filter. Thevolume between the circuit panel and the filter plate is filled with aliquid crystal material. This material will rotate the polarized lightwhen an electric field is applied between the circuit panel and atransparent ground electrode affixed to the filter plate or a coverglass. Thus, when a particular pixel of the display is turned on, theliquid crystal material rotates polarized light being transmittedthrough the material so that it will pass through the second polarizingfilter. Some liquid crystal materials, however, require no polarizers.LCDs may also have a passive matrix backplane which usually consists oftwo planes of strip electrodes which sandwich the liquid crystalmaterial. However, passive matrices generally provide a lower qualitydisplay compared to active matrices. Liquid crystal material includesbut is not limited to twisted nematic (TN), super TN (STN), double STN,and ferroelectric. U/DOP and EP displays are formed in a similar fashionexcept that the active medium is different (e.g., upconverting gas,downconverting gas, electrophoretic materials).

EL displays have one or more pixels which are energized by analternating current (AC) which must be provided to each pixel by row andcolumn interconnects. EL displays generally provide a low brightnessoutput because passive circuitry for exciting pixel phosphors typicallyoperates at a pixel excitation frequency which is low relative to theluminance decay time of the phosphor material. However, an active matrixreduces the interconnect capacitance allowing the use of high frequencyAC in order to obtain more efficient electroluminescence in the pixelphosphor. This results in increased brightness in the display.

LED displays are also used in flat-panel displays. LEDs emit light whenenergized. OLEDs operate like the LEDs except that OLEDs use organicmaterial in the formation of the diode.

Regardless of the type of active medium used, displays are generallycomprised of at least a substrate and a backplane. The backplane formsthe electrical interconnection of the display and comprises, in oneexample, electrodes, capacitors, and transistors in at least someembodiments of a backplane.

FIG. 1A illustrates a rigid display device wherein the active matrixdisplay backplane 10 is coupled to a rigid substrate 12. Typically, theactive matrix display backplane is also rigid. FIG. 1B shows anotherrigid display. There, the active matrix display backplane 10 is coupledto a rigid substrate 12 (e.g., glass). Also shown is a plurality ofblocks 14. These blocks may be fabricated separately and then depositedinto holes on substrate 12 by a process known as fluidic self-assembly(FSA). An example of the FSA process is described in U.S. Pat. No.5,545,291 issued to Stephen J. Smith, et al. These blocks may eachcontain driver circuitry (e.g., MOSFET and capacitor) for driving apixel electrode. The active matrix backplane includes transparent pixelelectrodes and row/column interconnects (not shown) to electricallyinterconnect the blocks 14. The plurality of blocks 14 is coupled to theactive matrix display backplane 10 and the rigid substrate 12. FIG. 1Cshows a reflective display 16 coupled to a rigid substrate 12. FIG. 1Dshows a reflective display 16 coupled to a rigid substrate 12. Aplurality of blocks 14 is coupled to the reflective display 16 and tothe rigid substrate 12.

Placing elements, such as pixel drivers, on a rigid substrate is wellknown. Prior techniques can be generally divided into two types:deterministic methods or random methods. Deterministic methods, such aspick and place, use a human or robot arm to pick each element and placeit into its corresponding location in a different substrate. Pick andplace methods generally place devices one at a time and are generallynot applicable to very small or numerous elements such as those neededfor large arrays, such as an active matrix liquid crystal display.

Random placement techniques are more effective and result in high yieldsif the elements to be placed have the right shape. U.S. Pat. No.5,545,291 describes a method which uses random placement. In thismethod, microstructures are assembled onto a different substrate througha fluid transport such FSA. Using this technique, various blocks, eachcontaining a functional component, may be fabricated on one substrateand then separated from that substrate and assembled onto a separaterigid substrate through the FSA process.

As noted above, FIGS. 1B and 1D illustrate a display substrate 12 withblocks 14 formed in the rigid substrate 12. These blocks 14 may bedeposited through an FSA process. In the FSA process, a slurrycontaining the blocks 14 is deposited over the rigid substrate 12 andthe blocks 14 rest in corresponding openings in the substrate 12.

FIG. 2 shows a planar side view of a rigid substrate coupled to a rigiddisplay backplane with a plurality of blocks 14 between the displaybackplane 30 and substrate 12. The plurality of blocks 14 arefunctionally part of the display backplane 30 and are deposited ontoreceptor regions of the substrate 12. Each block drives at least onetransparent pixel electrode. The pixel is fabricated over a transistorwhich is fabricated in the block.

FIG. 3 shows a portion of an array in an active matrix displaybackplane. The control line rows 31 and 32 in this device are coupled togate electrodes along a row and the control line columns 34 and 35 arecoupled to data drivers which supply pixel voltages which are applied tothe pixel electrodes. A column line 34 is connected to a sourceelectrode of field effect transistor (FET) 36. Another column line 35 iscoupled to a source electrode of FET 37. A row line 32 is coupled to thegates of both FETs 36 and 37. The drain of FET 36 is coupled throughcapacitor 38 to a transparent pixel electrode along the row 32 formed byFETs 36 and 37. The drain of FET 37 is coupled through a capacitor toanother pixel electrode along the row. In one typical example, thebackplane may be formed by depositing blocks, using an FSA technique,into a rigid substrate (e.g., glass); each block contains both a FET anda capacitor and is interconnected to other blocks by column and rowconductors which are deposited onto the rigid substrate; and, thecapacitor is coupled to a pixel electrode by another conductor which isdeposited onto the rigid substrate. The active medium (e.g., a liquidcrystal) is deposited at least on the pixel electrodes which willoptically change the active medium's properties in response to thecombined voltages or currents produced by the pixel electrodes. Theactive medium at a given pixel electrode 42 will appear as a square ordot in the overall checkerboard type matrix of the display. The actualsize of the FETs and the pixel electrodes 42 are not now drawn to scale,but are shown schematically for the purposes of illustration.

The interconnect between the rows and columns is comprised of flexibleand conductive material. For example, the interconnect could be made ofconductive polymers, metals (e.g., aluminum, copper, silver, gold,etc.), metal particles, teflon with metallic particles, or conductiveoxides. FIG. 4 shows pixel electrodes 46 on top of a substrate 49.

FIG. 4 shows a planar side view of a rigid substrate coupled to a rigiddisplay backplane with a plurality of blocks between the displaybackplane 30 and substrate 12. The plurality of blocks are functionallypart of the display backplane 30 and are deposited onto receptor regionsof the substrate 12. Each block drives at least one transparent pixelelectrode. The pixel is fabricated over a transistor which is fabricatedin the block.

Although there are displays which may be electronically updated, thesedisplays are nonetheless limited. For example, U.S. Pat. No. 5,465,085discloses a display which may be used to update information displayed onlabels in a retail store. However, these labels are not manufacturedsuch that the blocks with the circuit elements thereon are placed on asubstrate using FSA. Labels in which the circuit elements are placedonto the substrate using deterministic methods reduce productivity.

Another disadvantage to these flat-panel displays is that they aremanufactured in a batch operation. Batch operations inherently involve acertain amount of down time in production. This increases aggregateproduction time to fabricate display panels. Additionally, flat-paneldisplays are generally fabricated on rigid substrates which are notcontinuous in length. This also decreases productivity since theassembly of the flat-panel displays is interrupted until anothersubstrate panel is available to assemble the flat-panel display. It istherefore desirable to develop a system and a method that addresses thedisadvantages associated with conventional systems and methods.

SUMMARY

The present invention provides various apparatuses and methods forcreating displays. In one embodiment, the display may be conformal andthat may receive information in order to alter or configure the display.In another embodiment, a flexible layer may be made to receive an arrayof blocks that drive a display material in order to provide an alterableor configurable display. The receiver (and blocks) may be powered by thesignal from a transmitter which beams the information to the receiver.The receiver, in turn, controls the update of the display information onthe label.

While an array of components (e.g., display components) for an assemblyare described herein as examples of the invention, an array of otherassemblies such as x-ray detectors, radar detectors,micro-electro-mechanical structural elements (MEMS) or, generally, anassembly of sensors or actuators or an assembly of circuit elements alsomay be produced using the claimed invention. Thus, for example, flexibleantennas, other sensors, detectors, or an array of circuit elements maybe fabricated using one of the embodiments of the inventions. Otheraspects and methods of the present invention as well as apparatusesformed using these methods are described further below in conjunctionwith the following figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example. The invention isnot limited to the figures of the accompanying drawings in which likereferences indicate similar elements.

FIG. 1A shows a planar side view of an active matrix display backplanecoupled to a rigid substrate of the prior art.

FIG. 1B shows a planar side view of an active matrix display backplanecoupled to a rigid substrate wherein a plurality of blocks are part ofthe active matrix display of the prior art.

FIG. 1C shows a planar side view of a reflective display backplanecoupled to a rigid substrate of the prior art.

FIG. 1D shows a planar side view of a reflective display backplanecoupled to a rigid substrate wherein a plurality of blocks are coupledto the reflective display and to the rigid substrate of the prior art.

FIG. 2 shows a planar side view of a rigid substrate coupled to a rigiddisplay backplane with a plurality of blocks between the displaybackplane and substrate of the prior art.

FIG. 3 represents schematically a portion of an array of an activematrix backplane of the prior art.

FIG. 4 shows a top view of a plurality of pixel electrodes in abackplane of the prior art.

FIG. 5A shows a planar side view of a web material in accordance withone embodiment of the invention.

FIG. 5B shows a planar side view of a web material wherein recessedregions are created in the web material in accordance with oneembodiment of the invention.

FIG. 5C shows a planar side view of a web material with a receivercoupled thereto in accordance with one embodiment of the invention.

FIG. 5D shows the device in FIG. 5C in which blocks are placed onto theweb material in accordance with one embodiment of the invention.

FIG. 5E shows the device in FIG. 5D and a substrate in accordance withone embodiment of the invention.

FIG. 5F shows the device in FIG. 5E wherein the web material is coupledto the substrate in accordance with one embodiment of the invention.

FIG. 5G shows a transmitter emitting signals to the device in FIG. 5F inaccordance with one embodiment of the invention.

FIG. 6A shows a planar side view of web material in accordance with oneembodiment of the invention.

FIG. 6B shows a planar side view of web material with recessed regionscreated therein in accordance with one embodiment of the invention.

FIG. 6C shows a planar side view of web material with blocks placed inthe recessed regions in accordance with one embodiment of the invention.

FIG. 6D shows a substrate approach the web material with blocks inaccordance with one embodiment of the invention.

FIG. 6E shows a substrate coupled to the web material in accordance withone embodiment of the invention.

FIG. 6F shows the top view of a flexible display device wherein asubstrate is coupled to a receiver and the flexible display devicefunctions as a label in accordance with one embodiment of the invention.

FIG. 6G shows smart labels used in the keys of a keyboard in accordancewith one embodiment of the invention.

FIG. 7 shows a flow chart of the method of assembling a flexible displayalong the length of a flexible web material in accordance with oneembodiment of the invention.

FIG. 8 shows a flow chart of the method of manufacturing multipleflexible displays along the length of a flexible web material inaccordance with one embodiment of the invention.

FIG. 9 shows a top view of a flexible web material with multiple displaycomponents fabricated thereon in accordance with one embodiment of theinvention.

FIG. 10A shows a top view of a display component which has a passivematrix display backplane attached thereto in accordance with oneembodiment of the invention.

FIG. 10B shows a top view of a display component which has an activematrix display backplane attached thereto in accordance with oneembodiment of the invention.

FIG. 11 shows a top view of flexible web material attached to a displaybackplane in accordance with one embodiment of the invention.

FIG. 12A shows a planar side view of a backplane interconnect layercoupled to a flexible web material in accordance with one embodiment ofthe invention.

FIG. 12B shows a planar side view of a backplane interconnect layercoupled to a flexible web material wherein blocks are coupled to thebackplane interconnect layer and to the flexible web material inaccordance with one embodiment of the invention.

FIG. 12C shows a planar side view of a flexible reflective displaycoupled to a flexible web material which has holes or recesses to acceptblocks in accordance with one embodiment of the invention.

FIG. 12D shows a planar side view of a flexible reflective displaycoupled to a flexible web material which has holes or recesses to acceptblocks and a transmitter emitting signals in accordance with oneembodiment of the invention.

FIG. 13A shows a flow chart of a method of fabricating a display devicewherein a flexible web material and a display tape undergo processingand are subsequently coupled in accordance with one embodiment of theinvention.

FIG. 13B shows a method of fabricating a display device wherein aflexible web material and a display tape undergo processing and aresubsequently coupled in accordance with one embodiment of the invention.

FIG. 14 shows a flow chart of a method of the picking and placingobjects onto a flexible web material after the FSA process has beenapplied to the web material in accordance with one embodiment of theinvention.

FIG. 15 shows a flow chart which relates to the FSA process and thecoupling of the display material to the web material in accordance withone embodiment of the invention.

FIG. 16 shows a top view of a flexible continuous web material whereindisplays of different sizes are created in accordance with oneembodiment of the invention.

FIG. 17 shows a top view of a flexible continuous web material whereindisplays of similar size are created in accordance with one embodimentof the invention.

FIG. 18 shows a planar side view of the recessed regions in the webmaterial in accordance with one embodiment of the invention.

FIG. 19 shows a top view of display material being placed through ascreen onto display tape in accordance with one embodiment of theinvention.

FIG. 20 shows a top view of display material being laser etched ontodisplay tape in accordance with one embodiment of the invention.

FIG. 21 shows a top view of display material wherein lithography is usedto pattern the display material in accordance with one embodiment of theinvention.

FIG. 22 shows a top view of display material which is deposited in apattern onto display tape in accordance with one embodiment of theinvention.

FIG. 23A shows a planar side view of a web material in accordance withone embodiment of the invention.

FIG. 23B shows openings or receptor regions created and blocks depositedinto the web material in accordance with one embodiment of theinvention.

FIG. 23C shows deposition of planarization material and openings beingcreated into the web material in accordance with one embodiment of theinvention.

FIG. 23D shows deposition of interconnect and pattern interconnect inaccordance with one embodiment of the invention.

DETAILED DESCRIPTION

The present invention relates to apparatuses and methods for formingdisplays. The following description and drawings are illustrative of theinvention and are not to be construed as limiting the invention.

One embodiment of the invention relates to a smart label which has aflexible active matrix display panel coupled to a receiver. Byfabricating a smart label which is flexible, the smart label can befitted to an object which is either flexible or rigid and which has aplanar or a non-planar surface. This smart label may then receivesignals from a transmitter which updates information displayed on alabel. The backplane of the display may be comprised of a plurality ofblocks in which each block has a circuit element thereon. The blocks arecontained in a slurry which is deposited onto a flexible web material.Although blocks may be comprised of a single crystal silicon or otherlike material which makes the block rigid, the web material is stillflexible because the size of these blocks (50×100 microns or 100×100microns) is so small in comparison to the size of web material. Theflexible web material forms part of a display backplane. The flexibledisplays may be either an active matrix or a passive matrix displays. Itwill be appreciated that by using a web material (e.g., length to widthratio of for example, 80:1, 50:1, 25:1, 10:1, etc.), the fabrication ofsmart labels has a reduced cost compared to conventional batch processesthat are used.

Another embodiment of the invention relates to the blocks havingreceivers thereon.

Another embodiment of the invention relates to a flexible web materialwith a reflective display backplane.

Another embodiment of the invention involves using FSA generally with aflexible web processed material. Incorporated by reference is U.S. Pat.No. 5,545,291 explaining how to assemble microstructures onto asubstrate.

Another embodiment of the invention relates to the FSA process in which,after the blocks are deposited on the web material, the blocks fall intorecessed regions found in the web material. After a certain time period,the web material is checked for any existing empty recessed regions. Theweb material is checked by an electronic eye secured to a machine whichis able to view the surface of the web material. A robot or a person isused to place an object on an empty recessed region.

In the following description, numerous specific details such as specificmaterials, processing parameters, processing steps, etc., are set forthin order to provide a thorough understanding of the invention. Oneskilled in the art will recognize that these details need not bespecifically adhered in order to practice the claimed invention. Inother instances, well known processing steps, materials, etc. are notset forth in order not to obscure the invention.

FIGS. 5A-5E and FIGS. 6A-6E show embodiments of the invention in whichweb material is able to receive objects. Although these embodimentsrelate to web material, other flexible or rigid substrates may be usedin place of the web material.

FIGS. 5A-5E show the assembly of one embodiment of a smart label. FIG.5A shows a web material 50. FIG. 5B shows web material 50 with differentsized recessed regions that were made into the web material using amethod such as a roller having protruding members. FIG. 5C shows areceiver 58 placed into a recessed region. FSA is used to place thereceiver into the recessed regions of the web material. A wireless RFtransponder is the preferred type of receiver 58 because it isnoncontact and needs only one chip. However, other types of receiversmay be used. The receiver operates in a typical fashion and may includea detector, a plurality of amplifiers, a pitch detector, comparator, anda bias generator. The display also may incorporate a power supply thatincludes both photo-voltaic cell and a power control system thatcontrols power through the lines.

FIG. 5D shows blocks with integrated circuits thereon placed intorecessed regions of the web material 50. The blocks are placed into therecessed regions by FSA or a deterministic method such as “pick andplace.” FIG. 5E shows a substrate 52 before it is coupled to the devicein FIG. 5D. FIG. 5F shows substrate 52 coupled to web material 50 andreceiver 58 in the web material. FIG. 5G shows a transmitter emittingsignals to the receiver 58 of the device shown in FIG. 5F. The signalfrom the transmitter is received by a receiver on substrate 52. Thereceiver, coupled to the plurality of blocks, transmits the signal tothe blocks. The blocks, in turn, cause the display to change.

FIG. 5G also shows a smart label (e.g., display) detecting a signal froma device (e.g. a transmitter, transceiver, etc.) that is capable oftransmitting a signal. The device sending the signal may be portable orit may be an add-in board for a computer in which the transmitter isconnected to a conventional bus. The data contained in a signal andreceived by a receiver in the smart label may contain such informationas an address, a command, data related to updating information on adisplay, or any other data. The receiver then may amplify the signalsthat are either “1” or “0” and reconstructs the data into bit times. Forexample, a long bit time may represent “1” and a short bit time mayrepresent “0”. A controller, coupled to a display, may then compare anaddress in the signal with one stored in the controller itself. If theaddresses match, the message is decoded. If there is not match betweenthe addresses, the message is disregarded. It will be appreciated thatthe smart label may require a security code that must be first used in afirst signal before a second signal may update the display. This willprevent an unscrupulous third party from sending a code that causes thedisplay to change when there is no authorization to change the display.

A power source (not shown) such as a solar cell may be used to power acontroller (not shown). The controller in turn may be used to power theblocks in the display. One embodiment of the invention involvesincorporating a controller onto a block. This allows a portable device(e.g. transmitter or transceiver) to transmit signals directly to blockson a smart label allowing the display to be updated. While FIG. 5Gdescribes one method of powering a display, many other known methodsalso may be used.

FIGS. 6A-6E show the assembly of another embodiment of a smart label inwhich a receiver is on each block. FIG. 6A shows a planar side view ofweb material 50. FIG. 6B shows a planar side view of web material withrecessed regions created in the web material 50. FIG. 6C shows blocks 15with electronic devices (e.g., integrated circuits, photocell, LED,capacitors, fuses, MEM sensor or other suitable device) thereon seatedin the recessed regions or holes in the web material 50. FIG. 61) showsthe substrate 52 before it is coupled to the web material 50. FIG. 6Eshows the substrate 52 coupled to the web material 50. Bistable liquidcrystal may be used in conjunction with the flexible substrate 52 tocreate a bistable liquid crystal cell between the substrate and the webmaterial. Bistable liquid crystal allows the display to stay in such astate that there is no need to refresh the display and the display willremain in its last set state until new data is written into the display.A display of this type may be used in credit cards, labels in grocerystores, or any other type of card or label. Blocks are deposited ontothe flexible substrate and are part of the active matrix displaybackplane. A block comprises an active circuit element (not shown) whichdrives a picture element (not shown). Blocks receive data as well asoutput data thereby creating a display. FIG. 6F shows the top view of aflexible display device wherein a substrate is coupled to a wirelessreceiver and to a label, FIG. 6G shows smart labels used in the keys ofthe keyboard. The keyboard may be attached to a computer or any otherdevice which requires information to be inputted. By creating alterabledisplays on keys, the keypad may be may be electronically modified toreflect a foreign language such as French, German or Japanese. Thisreduces costs because the keyboard does not have to be physicallyreplaced when using a dramatically different language.

FIG. 7 shows one method of assembling a flexible display along thelength of a flexible web material at operation 70 in accordance with anembodiment of the invention. Blocks are assembled into the openings ofthe flexible web material. Utilizing an FSA process, a plurality ofblocks are deposited in a slurry. The slurry is then placed over aflexible substrate and the blocks go into the recessed regions of theflexible substrate.

Planarization of the assembly of blocks into web material 72 is the nextoperation. Extrusion bar coating is one of many methods that may be usedto planarize web material. Then, the electrical coupling of theplurality of blocks takes place at operation 74 by opening holes in theplanarization layer and depositing metalization material or otherconductive materials into the holes and beyond the holes to form aninterconnect (e.g., a row or column interconnect). The web materialholding the plurality of blocks may then be coupled to another flexiblelayer such as web material at operation 76. The display is made toconform the object's shape at operation 78. The operation for formingthe display may be done in a different order than that found in FIG. 7and thus the operation 78 may be performed after operation 80. A displaygeneration substrate (e.g., bistable liquid crystal, polymer-dispersedliquid crystal, or other material) is coupled to the active matrixbackplane at operation 80.

FIG. 8 shows a method of manufacturing multiple displays along aflexible web material (or a flexible substrate). Multiple displaycomponents are created on a flexible web material at operation 200. Theflexible web material is advanced to a second region on the web materialat operation 202. A new display component is created on the flexible theweb material in a different region of the web material at operation 204by advancing the flexible web material through a web processingapparatus at operation 206 and coupling a display material to the webmaterial at operation 208. Separation of the display panel occurs at theend of the process at operation 210.

FIG. 9 shows a flexible web material with multiple display componentsthat may be used to implement techniques of the invention. The flexibleweb material 220 has display component 222 and display component 224attached thereto. The web material has three lengths: a first length226, a second length 228, and a third length 230. Display components 222and 224 are active matrix display devices.

FIG. 10A shows display component 222 which has a passive matrix displaybackplane attached thereto which may be used in accordance with oneembodiment of the invention. Substrate 52 is coupled to web material 50.FIG. 10B shows a display component 39 which has an active matrix displaybackplane attached thereto.

FIG. 11 shows a web material 50 coupled to flexible substrate 52, to adisplay backplane and to a receiver 58 in accordance with one embodimentof the invention.

FIG. 12A shows a reflective display backplane 48 coupled to a flexibleweb material 43. FIG. 12B shows a flexible reflective display backplane48 coupled to a web material 43 in which blocks 54 are coupled to theflexible web material 43 and to the flexible reflective displaybackplane 48. The reflective display backplane includes an interconnectlayer 45. Interconnect layer 45 typically is comprised of metallicmaterial or other conductive material. Coupled to the flexible webmaterial 43 is a flexible reflector 47. FIG. 12C shows a flexiblereflective display wherein recessed region 51 contains reflectivematerial 44. The web material 43 is coupled to the reflective displaybackplane 48. FIG. 12D shows a receiver 58 coupled to the reflectivedisplay which forms a portion of the smart label. A second web material(not shown) is coupled to the device of FIG. 12D. This second webmaterial has display material.

FIG. 13A shows a method of fabricating a display device in which aflexible web material and a display tape undergo processing and aresubsequently coupled. There, the flexible web material is advanced alonga process line at operation 500. A slurry containing a plurality ofblocks is dispensed onto the flexible web material at operation 502. Asecond slurry containing a plurality of blocks is again dispensed ontothe web material. Excess slurry is collected in a container and isrecycled. The blocks fall into recessed regions in the web material atoperation 502. Adhesives and spacers are deposited onto the web materialat operation 504. Display material is placed onto the web material atoperation 508. This material may comprise bistable liquid crystal,polymer-dispersed liquid crystal, cholesteric liquid crystal,electrophoretic liquid crystal, upconverting phosphor, or downconvertingphosphor at operation 512. Instead of placing blocks onto the webmaterial, a substrate may be made to receive the blocks when creatingthe display. The web material may then be coupled to the substrate.

FIG. 13B shows the overall process of fabricating a display devicewherein a flexible web material 120 and a substrate 160 (or another webmaterial) undergo processing and are subsequently coupled. There, theflexible web material is advanced along a first process line andadvances through a first set of support members 122. A first slurry 124containing a plurality of blocks is dispensed onto the flexible webmaterial. A second slurry 126 containing a plurality of blocks is againdispensed onto the web material. Excess slurry is collected in acontainer 128 and is recycled. The blocks fall into recessed regions inthe web material. Flexible web material 120 is advanced through a secondset of support members 130. An interconnect 132 is then deposited ontoflexible web material 120. The flexible substrate is then advanced topoint 134. In conjunction with this process, substrate 160 undergoes aseparate process. Display material is placed onto at least one side ofthe substrate 160. Substrate (or another web material) 160 is advancedthrough a first set of support members 164. The display material ispatterned or layered 169. This display material may comprisepolymer-dispersed liquid crystal, cholesteric liquid crystal, bistableliquid crystal, electrophoretic liquid crystal, upconverting phosphor,or downconverting phosphor. Substrate 160 is advanced through a secondset of support members 170. An interconnect 172 is either deposited oretched onto the substrate 160. The substrate is then advanced to point134 where the substrate is coupled to the web material. A conveyor belt174 surrounds the support members. A PDLC layer may be used that canhave indium tin oxide (ITO) attached thereto wherein they are laminatedtogether; or, the ITO can be coupled to a substrate and sealed.

FIG. 14 relates to a method of picking and placing of objects onto aflexible web material after the FSA process has been applied to the webmaterial. A slurry containing a plurality of objects is dispensed ontothe web material at operation 90. The objects fall into recessed regionsin the web material. The excess slurry is collected and recycled atoperation 91. The web material is checked for empty recessed regions atoperation 92. This checking is performed by an electronic eye whichviews the substrate. Objects are robotically placed into empty regionsfound in the web material at operation 94. A metalization material isplaced onto at least one of the web material's surfaces and is patternedor etched at operation 96. The web material is coupled to the webmaterial at operation 98.

FIG. 15 relates to the FSA process and the coupling of the displaymaterial with the web material. At operation 431, a determination ismade by an operator whether the recessed regions in the substrate are ofequivalent size. A slurry containing a plurality of blocks is dispensedonto the web material at operation 410. If the recessed regions are ofequivalent size, operation 450 is then followed. (At operation 450, aslurry containing a plurality of objects is disposed onto web material.The plurality of objects slide into recessed regions in the webmaterial. The excess slurry is caught and recycled at operation 460.) Ifnot, a first slurry with a first plurality of objects is deposited ontothe web material at operation 410. Excess slurry is caught and recycledat operation 415. Once this step is performed, a second slurry with asecond plurality of objects is placed onto the web material at operation420. Excess second slurry is recycled into a second container atoperation 425. A metal interconnect is then deposited onto the webmaterial at operation 435. After these steps, a display material isdeposited onto a display tape or a second web material at operation 437.

FIG. 16 shows a flexible continuous web material wherein two displaysare created. Display device 62 is larger than display device 53. Thisshows that multiple displays of different sizes can be created on theweb material through an in-line process. Alternatively, FIG. 17 showsdisplays 64 and 56 of similar size.

In addition to multiple displays being able to be made different sizes,the web material itself may have different sized recessed regions. Thisallows the web material to receive various sized blocks or devices. FIG.18 shows a cross-sectional view of the recessed regions in thesubstrate. Recessed region 65 is smaller than recessed region 67.

FIG. 19 shows a display material being placed through a screen ontodisplay tape. The screen has a desired pattern created by holes which gothrough the screen. This pattern may be dictated by a customer or by themanufacturer.

Another method of placing display material onto the display tape isshown in FIG. 20. FIG. 20 shows a top view of display material beinglaser etched onto display tape. The etching occurs when the highintensity light from the laser strikes the display material on top ofthe display tape. A pattern is created in the display material by thelaser.

Another method of depositing display material is shown in FIG. 21. FIG.21 shows lithography being used to pattern the display material.Lithography involves using a block with a pattern engraved in the bottomsurface of the block. The bottom surface of the block contacts thedisplay material.

FIG. 22 shows yet another method of depositing display material onto thedisplay tape. There display material is deposited in a pattern onto thedisplay tape. The display material is deposited by a container whichcontains the display material. The container is placed over the displaytape. The display material drops onto the display tape 168 in a pattern.

FIGS. 23A-23D show generally the process of planarization material beingadded onto the web material (or flexible substrate if blocks are placedonto a flexible substrate instead of web material). Planarization of webmaterial may occur through a variety of methods. One method involvesusing extrusion bar coating. FIG. 23A shows a planar side view of a webmaterial 190. FIG. 231 shows openings or receptor regions 192 createdand blocks deposited into the web material. FIG. 23C shows deposition ofplanarization material 194 and openings being created into the webmaterial. FIG. 23D shows deposition of interconnect 198 and patterninterconnect.

While an array of components (e.g. display components) for an assemblyhave been described as examples of the invention, an array of otherassemblies such as x-ray detectors, radar detectors,micro-electro-mechanical structural elements (MEMS) or, generally, anassembly of sensors or actuators or an assembly of circuit elements alsomay be produced using the claimed invention. Thus, for example, flexibleantennas, other sensors, detectors, or an array of circuit elements maybe fabricated using one of the embodiments of the inventions. Otheraspects and methods of the present invention as well as apparatusesformed using these methods are described further below in conjunctionwith the following figures.

Listed below is a related U.S. patent describing methods and devicesthat may be used in the invention described herein. This U.S. patent isincorporated by reference. Additionally, previously filed patentapplications are also incorporated by reference. These patentapplications are also incorporated by reference.

U.S. Pat. No. 5,545,291 entitled “Method for Fabricating Self-AssemblingMicrostructures,” filed by John S. Smith and His-Jen J. Yeh, issued Aug.13, 1996.

Co-pending U.S. patent application Ser. No. 09/270,146 entitled“Apparatuses and Methods for Forming Assemblies,” (Docket No.003424.P008), filed by Jeffrey J. Jacobsen and assigned to the sameAssignee as the present invention, describes a method and apparatus ofassembling flexible displays. This co-pending application is herebyincorporated herein by reference.

Co-pending U.S. patent application Ser. No. 09/270,157 entitled “Methodsfor Transferring Elements From A Template To A Substrate” (Docket No.003424.P009), filed by Jeffrey J. Jacobsen, Mark A. Hadley, and JohnStephen Smith and assigned to the same Assignee of the presentinvention, describe an PSA on a template with transfer to anothersubstrate. These co-pending applications are hereby incorporated hereinby reference.

Co-pending U.S. patent application Ser. No. 09/270,159 entitled “Methodsand Apparatuses for Fabricating A Multiple Module Assembly” (Docket No.003424.P010), filed by Jeffrey J. Jacobsen, Glenn Wilhelm Gengel, andGordon S. W. Craig and assigned to the same Assignee as the presentinvention, describes an electronic modular assembly. This co-pendingapplication is hereby incorporated herein by reference.

Co-pending U.S. patent application Ser. No. 09/270,147 entitled“Apparatuses and Methods Used in Forming Electronic Assemblies” (DocketNo. 003424.P011), filed by Jeffrey J. Jacobsen, Glenn Wilhelm Gengel,and John Stephen Smith and assigned to the same Assignee as the presentinvention, describes a method of molding substances. This co-pendingapplication is hereby incorporated herein by reference.

Co-pending U.S. patent application Ser. No. 09/270,165 entitled“Apparatuses and Methods for Forming Assemblies” (Docket No.003424.P016), filed by Jeffrey J. Jacobsen and assigned to the sameAssignee as the present invention, described a method of rolling blocksinto their recessed regions. This co-pending application is herebyincorporated herein by reference.

Co-pending U.S. patent application Ser. No. 09/932,409 entitled“Apparatuses and Methods for Forming Assemblies” (Docket No.003424.P021), filed by Mark A. Hadley, Ann Chiang, Gordon Craig, JeffreyJay Jacobsen, John Stephen Smith, Jay Tu, and Roger Stewart and assignedto the same Assignee as the present invention, describes a relocatingtool capable of moving a plurality of blocks from a first substrate to asecond substrate.

In the preceding detailed description, the invention is described withreference to specific embodiments thereof. It will, however, be evidentthat various modifications and changes may be made thereto withoutdeparting from the broader spirit and scope of the invention as setforth in the claims. The specification and drawings are, accordingly, tobe regarded in an illustrative rather than a restrictive sense.

1. A method for manufacturing of an apparatus comprising: disposing aplurality of metallization patterns on a web material, the length towidth ratio of the web material being greater than 10:1; roboticallyplacing a plurality of radio frequency (RF) transponder chips onto theweb material, each of the RF transponder chips respectively coupled toat least one of the metallization patterns; and after the disposing andthe robotically placing, separating the web material to form assemblies,each of the assemblies including a single RF transponder chip, whereineach of the RF transponder chips are configured to be powered by asignal from a transmitter and to store a security code.
 2. The method ofclaim 1 wherein the metallization patterns comprise silver particles. 3.The method of claim 1 further comprising applying an adhesive to the webmaterial.
 4. The method of claim 1 wherein the RF transponder chips arenoncontact devices.
 5. The method of claim 1 further comprising couplingthe web material to a second web material.
 6. The method of claim 1wherein the ratio is greater than 50:1.
 7. The method of claim 1 whereinthe apparatus comprises a display, the display configured to displayinformation related to a retail product.
 8. The method of claim 7wherein the apparatus further comprises a controller configured tocontrol the information on the display.
 9. The method of claim 1 whereinthe apparatus comprises a flexible antenna.